WO2023282034A1

WO2023282034A1 - Support film reusability determination method, support film cleaning method, support film reuse method, support film roll production method, transfer laminated film roll production method, support film reusability determination program, and support film reusability determination system

Info

Publication number: WO2023282034A1
Application number: PCT/JP2022/024438
Authority: WO
Inventors: 康大久保; 修増田; 太平伊香賀; 浩西村; 公志田坂; 崇南條
Original assignee: コニカミノルタ株式会社
Priority date: 2021-07-08
Filing date: 2022-06-20
Publication date: 2023-01-12
Also published as: KR20240013222A; JPWO2023282034A1; CN117716229A

Abstract

The present invention addresses the problem of providing a support film reusability determination method, a support film reusability determination program, and a support film reusability determination system which enable efficient and highly accurate determination on the reusability of a support film used in producing a laminated body by a release and transfer method, and also providing a support film cleaning method, a support film reuse method, a support film roll production method, and a transfer laminated film roll production method which adopt the support film reusability determination method.　This support film reusability determination method is characterized by comprising: a measurement step for measuring, while conveying a support film, data relating to a transfer film residue remaining on the support film by using an optical measuring means; and a determination step for determining, on the basis of the data relating to the measured transfer film residue, reusability including the necessity of cleaning of the support film.

Description

A support film reusability determination method, a support film cleaning method, a support film reuse method, a support film roll manufacturing method, a transferable laminated film roll manufacturing method, a support film reusability determination program, and Support film reusability judgment system

The present invention provides a method for determining reusability of a support film, a method for washing a support film, a method for reusing a support film, a method for manufacturing a support film roll, a method for manufacturing a transferable laminated film roll, and reusability of a support film. The present invention relates to a determination program and a support film reusability determination system.
More specifically, the present invention relates to a support film reusability determination method capable of efficiently and accurately determining whether or not a support film used in laminate production by a peel transfer method can be reused.

Recently, many foldable flexible displays have been developed. In order to provide the foldability required for the display, thinning of various films used for the display is strongly desired.
On the other hand, it is known that workability and yield in actual processes decrease as the film becomes thinner. For example, when a thin film with a thickness of 20 μm or less is transported in a process, the stiffness and strength of the entire film decreases, so the frequency of problems such as curling, folding, and breaking increases rapidly, resulting in process contamination and a decrease in yield. Big problems can occur.

In order to solve such problems, attempts have recently been made to provide an optical film in the form of a peel-off transfer type. Such an optical film is provided in a form integrated with a support film capable of imparting process suitability to the optical film, and the optical film provided as an upper layer is laminated, peeled, and transferred to a desired position. This has the advantage that only very thin optical films can be provided for products such as laminates.

However, even in this peel-and-transfer type provision form, if the thickness of the optical film to be transferred (hereinafter also referred to as "transferred film") is, for example, 10 μm or less, the strength of the film itself is reduced, so the transfer process is difficult. It has been found that there is a problem that the peeling residue due to breakage or tearing is likely to occur due to disturbance. For example, when it is assumed that an optical film having a thickness of 3 μm is to be transferred, it is not difficult to imagine that a film thickness variation of ±0.5 μm or a foreign matter on the support film would cause a serious problem.

In addition, for example, when such an ultra-thin film is provided by coating it on a support film, the surface quality of the ultra-thin film is greatly related to the quality of the support. However, such high-quality support films are not only expensive, but also have long lead times.

As a solution to such problems, it is considered effective to reuse the support film that becomes unnecessary after use in such a peel-and-transfer type usage method. For example, if the customer can receive the remaining support film after the production is completed, the support film can be secured according to the customer's consumption and the support with reduced lead time and cost can be secured. Furthermore, since the customer's production status can also be estimated, there is an advantage in terms of production planning that it is possible to shorten the delivery time by visualizing the entire production plan.

Therefore, in building a business model that incorporates the reuse of such support films, it is essential to have a method that can efficiently and accurately inspect the peeling residue on the support film and determine whether it can be reused. .

As a system for inspecting the film surface, for example, an inspection system capable of determining the composition of the resin layer of a resin sheet has been disclosed (see Patent Document 1). However, since such an inspection system is intended to inspect the composition of the resin sheet itself, it is possible to efficiently and accurately inspect the peeling residue of the transfer-receiving film formed on the support film. I couldn't.

JP 2019-86412 A

The present invention has been made in view of the above problems and situations, and the problem to be solved is that it is possible to efficiently and highly accurately determine whether the support film used in the production of a laminate by the peel transfer method can be reused. Support film reusability determination method, reusability determination program, reusability determination system, support film cleaning method using support film reusability determination method, support film reuse method, support film An object of the present invention is to provide a method for manufacturing a roll and a method for manufacturing a transferable laminated film roll.

In order to solve the above problems, the present inventors have investigated the causes of the above problems, etc., and found that while conveying the support film used in the production of the laminate by the peel transfer method, the support was measured using an optical measuring means. It has a measurement step of measuring data related to the transfer-receiving film residue remaining on the film, and a judgment step of judging whether or not it can be reused based on the measured data. The inventors have found that it is possible to provide a method for determining the reusability of a support film, which can efficiently and highly accurately determine the reusability of a support film that has been processed, and have arrived at the present invention.
That is, the above problems related to the present invention are solved by the following means.

1. A method for determining the reusability of a support film used in laminate production by a peel transfer method,
a measuring step of measuring data relating to a transfer-receiving film residue remaining on the support film using an optical measuring means while transporting the support film;
and determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue.

2. Before the measurement step, a measurement condition setting step for the optical measurement means,
In the measurement condition setting step, setting the measurement condition to a measurement condition that emphasizes the thickness or material of the transfer-receiving film residue based on the data regarding the transfer-receiving film formed on the support film. 2. The method for determining reusability of the support film according to item 1.

3. the measuring step comprises at least a first measuring step and a second measuring step;
In the first measuring step, measuring the position of the transfer-receiving film residue;
3. Judgment on reusability of the support film according to claim 1 or 2, characterized in that in the second measuring step, the thickness or material of the transfer-receiving film residue remaining at the position is measured. Method.

4. A method for cleaning a support film used in laminate production by a peel transfer method, comprising:
When it is determined that cleaning is necessary by the method for determining the reusability of a support film according to any one of items 1 to 3, based on the measured data on the transfer film residue, the A method for washing a support film, comprising removing a transfer-receiving film residue remaining on the support film.

5. A method for reusing a support film used in laminate production by a peel transfer method,
The support film determined not to require cleaning by the method for determining reusability of the support film according to any one of items 1 to 3, or the method for cleaning the support film according to item 4. A method for reusing a support film, comprising: reusing the support film washed by the method as a support for a transfer-receiving film.

6. A method for manufacturing a support film roll, which is a roll of a support film, comprising:
The support film determined not to require cleaning by the method for determining reusability of the support film according to any one of items 1 to 3, or the method for cleaning the support film according to item 4. A method for producing a support film roll, comprising: winding up the support film washed by the above method to produce a support film roll.

7. A method for producing a transferable laminated film roll, which is a roll body of a transferable laminated film, comprising:
The support film determined not to require cleaning by the method for determining reusability of the support film according to any one of items 1 to 3, or the method for cleaning the support film according to item 4. A transferable laminated film is produced by laminating a transfer-receiving film on the support film washed by the method, and the transferable laminated film is wound up to produce a transferable laminated film roll A method for manufacturing a laminated film roll.

8. A program for determining the reusability of a support film used in laminate production by a peel transfer method,
a measuring step of measuring data relating to a transfer-receiving film residue remaining on the support film using an optical measuring means while transporting the support film;
determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue. program.

9. A system for determining the reusability of a support film used in laminate production by a peel transfer method,
a conveying means for conveying the support film;
optical measuring means for measuring data relating to transfer-receiving film remnants remaining on the support film during transportation;
and determination means for determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue.

A method for determining the reusability of a support film, a program for determining the reusability of a support film, and a program for determining the reusability of a support film, which can efficiently and accurately determine whether or not the support film used in the production of a laminate by a peel transfer method can be reused by the means of the present invention; A reusability determination system, a support film cleaning method using the support film reusability determination method, a support film reuse method, a support film roll manufacturing method, and a transferable laminated film roll manufacturing method can provide.

Flowchart showing an example of an embodiment of a reusability determination method Flowchart showing an example of an embodiment of a reusability determination method Flowchart example after reusability determination Flowchart example after reusability determination Schematic diagram seen from the front in the width direction showing an example of optical measurement means Schematic diagram showing an example of the first optical measuring means viewed from the front in the widthwise direction Schematic diagram showing an example of the second optical measuring means viewed from the front in the widthwise direction Schematic diagram showing an example of the second optical measuring means as viewed from the front in the conveying direction Installation example of blast nozzle and suction nozzle in dry ice blasting Installation example of blast nozzle and suction nozzle in dry ice blasting Schematic diagram showing an example of an optical film roll manufacturing apparatus Example: Block diagram of reusability determination system used in reusability determination (1) Example: Block diagram of reusability determination system used in reusability determination (2) Example: Flowchart of Reusability Judgment (1) Example: Flowchart of Reusability Judgment (2)

The method for determining the reusability of a support film of the present invention is a method for determining the reusability of a support film used in the production of a laminate by a peel transfer method, wherein the support film is conveyed while an optical measuring means is measured. a measurement step of measuring data relating to the transfer-receiving film residue remaining on the support film using and a judgment step for judging reusability.
This feature is a technical feature common to or corresponding to the following embodiments.

As an embodiment of the method for determining the reusability of a support film of the present invention, the step of setting measurement conditions for the optical measurement means is provided before the measurement step, and in the measurement condition setting step, on the support film It is preferable to set the measurement conditions to emphasizing the thickness or material of the transfer-receiving film remnants based on the data on the transfer-receiving film formed in the above. As a result, it is possible to determine whether or not an item can be reused at high speed and with high accuracy.

As an embodiment of the method for determining reusability of a support film of the present invention, the measuring step comprises at least a first measuring step and a second measuring step, and in the first measuring step, It is preferable that the position of the object is measured, and the thickness or material of the transfer-receiving film residue remaining at the position is measured in the second measuring step. This makes it possible to more efficiently determine whether or not the item can be reused.

The method for cleaning a support film of the present invention is a method for cleaning a support film used in the production of a laminate by the peel-transfer method, and it is determined that cleaning is necessary by the method for determining reusability of a support film of the present invention. In this case, the transfer-receiving film remnants remaining on the support film are removed based on the measured data relating to the transfer-receiving film remnants.

The method for reusing a support film of the present invention is a method for reusing a support film that has been used in the production of a laminate by the peel-transfer method, and is judged by the method for determining reusability of a support film of the present invention that washing is unnecessary. The support film, or the support film washed by the method for washing a support film of the present invention, is reused as a support for producing a transferred film.

The method for manufacturing a support film roll of the present invention is a method for manufacturing a support film roll, which is a roll body of a support film, and was determined not to require washing by the method for determining reusability of a support film of the present invention. A support film roll is manufactured by winding up the support film or the support film washed by the method for washing a support film of the present invention.

The method for producing a transferable laminated film roll of the present invention is a method for producing a transferable laminated film roll, which is a roll body of a transferable laminated film, and cleaning is unnecessary by the method for determining whether or not a support film can be reused according to the present invention. A transfer-receiving film is laminated on the determined support film or the support film washed by the method for washing a support film of the present invention to prepare a transferable laminated film, and the transferable laminated film is produced. It is characterized in that it is wound up to produce a transferable laminated film roll.

A program for determining the reusability of a support film of the present invention is a program for determining the reusability of a support film used in the production of a laminate by a peel transfer method, wherein the support film is transported while an optical measuring means is measured. a measurement step of measuring data relating to the transfer-receiving film residue remaining on the support film using and a judgment step for judging whether or not reuse is possible.

The support film reusability determination system of the present invention is a support film reusability determination system used in laminate production by a peel transfer method, comprising a transport means for transporting the support film, Optical measuring means for measuring data on the transfer-receiving film residue remaining on the support film, and whether or not the support film needs to be washed based on the measured data on the transfer-receiving film residue. and determination means for determining whether or not the device can be reused.

The following is a detailed description of the present invention, its components, and the forms and modes for carrying out the present invention. In the present application, "-" is used to mean that the numerical values before and after it are included as the lower limit and the upper limit.

<Outline of method for judging reusability of support film>
The method for determining the reusability of a support film of the present invention is a method for determining the reusability of a support film used in the production of a laminate by a peel transfer method, wherein the support film is conveyed while an optical measuring means is measured. a measurement step of measuring data relating to the transfer-receiving film residue remaining on the support film using and a judgment step for judging reusability.

In addition, before the measuring step, a measuring condition setting step for the optical measuring means is provided, and in the measuring condition setting step, based on the data regarding the transferred film formed on the support film, the It is preferable to set the measurement conditions so that the thickness or material of the transfer-receiving film residue is emphasized. As a result, it is possible to determine whether or not the item can be reused with higher accuracy.

Further, the measuring step includes at least a first measuring step and a second measuring step, wherein the first measuring step measures the position of the transfer-receiving film residue, and the second measuring step measures the position of the transfer-receiving film residue. It is preferable to measure the thickness or material of the transfer-receiving film residue remaining at the position. This makes it possible to more efficiently determine whether or not the item can be reused.

"Laminate production by peeling transfer method" means that from a transferable laminated film having a transfer film (for example, an optical film such as a zero retardation film) on a support film, another substrate etc. is peeled off while peeling the transfer film. It refers to a production method for producing a laminate (for example, a polarizing plate) by transferring and bonding to (for example, a substrate on which a polarizer is formed).

In the method for determining the reusability of the support film of the present invention, the reusability is determined for the support film used in the production of the laminate by such a peel transfer method.

"Reuse of the support film" in the present invention means reuse as the support film. In other words, it refers to reuse as a support film in the production and transport of a transferable laminated film, and does not include recycling (reuse) for other uses.

"Transferred film residue" refers to the peeled residue of the transferred film in the peel-transfer process.

The "support film" that is subject to reusability refers to the film that supports the transfer-receiving film when the transfer-receiving film is formed. The constituent base material of the support film is a general resin film, and may contain various additives.

The thickness, material, configuration, etc. of the support film are not particularly limited from the viewpoint of reusability determination, but from the viewpoint of reuse, for example, the following are preferable.

The thickness of the support film is preferably 200 μm or less. The thickness of the support film is preferably within the range of 25 to 125 μm, more preferably within the range of 35 to 100 μm, since the support requires a certain degree of strength (resilience and rigidity).

Examples of the resin used for the support film include cellulose ester-based resins, cycloolefin-based resins, polypropylene-based resins, acrylic-based resins, polyester-based resins, polyarylate-based resins, and styrene-based resins. A species or two or more species can be used. Among these, it is preferable to use a polyester-based resin as a resin that is excellent in storage stability in a high-humidity environment.

Examples of polyester resins include polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polybutylene naphthalate (PBN). Among them, polyethylene terephthalate (PET) and polyethylene naphthalate (PEN) are preferable from the viewpoint of ease of handling.

The resin film may be heat-treated (heat-relaxed) or stretched.

The heat treatment is a treatment for reducing the residual stress of the resin film (for example, the residual stress associated with stretching), and is not particularly limited. ~(Tg+180)°C.

The stretching process is a process for increasing the residual stress of the resin film, and the stretching process is preferably carried out, for example, in the biaxial directions of the resin film. The stretching treatment can be performed under arbitrary conditions, for example, at a stretching ratio of about 120 to 900%. Whether or not the resin film is stretched can be confirmed by checking, for example, whether or not there is an in-plane slow axis (an axis extending in the direction in which the refractive index is maximized). The stretching treatment may be performed before laminating a functional layer such as a release layer or an easy-adhesion layer described below, or after lamination.

Commercially available polyester resin films (simply referred to as polyester films) can be used. Therapeal SY/HP2/PJ101 (manufactured by Toray Industries, Inc.) and the like can be preferably used.

The support film may further have a release layer provided on the surface of the resin film. The release layer can make it easier to separate the support film and the transferred film when producing a laminate such as a polarizing plate.

The release layer may contain a known release agent, and is not particularly limited. Examples of release agents contained in the release layer include silicone release agents and non-silicone release agents.

Examples of silicone-based release agents include known silicone-based resins. Examples of non-silicone release agents include long-chain alkyl pendant type polymers obtained by reacting long-chain alkyl isocyanate with polyvinyl alcohol or ethylene-vinyl alcohol copolymer, olefin resins and waxes (e.g. copolymerized polyethylene, polypropylene , cyclic polyolefins, polymethylpentene, carnauba wax, etc.), polyarylate resins (e.g., polycondensates of aromatic dicarboxylic acid components and dihydric phenol components), fluororesins (e.g., polytetrafluoroethylene (PTFE), polyfluoride Vinylidene chloride (PVDF), polyvinyl fluoride (PVF), PFA (copolymer of tetrafluoroethylene and perfluoroalkoxyethylene), FEP (copolymer of tetrafluoroethylene and hexafluoropropylene), ETFE (tetrafluoro ethylene and ethylene copolymers)), styrene, (meth)acrylic resins, and the like. Preferably, it is a non-silicone type release agent that is difficult to transfer to the transfer-receiving film.

The thickness of the release layer is not particularly limited as long as it can exhibit the desired releasability, but is preferably 0.1 to 1.0 μm, for example.

In addition, a support film having an easy-adhesion layer may be used in order to provide higher adhesiveness to the transfer-receiving film. Examples of the easy-adhesion layer include polyolefin-based and polyester-based resins, polyacrylamide-based polymers; vinyl alcohol-based polymers such as polyvinyl alcohol and ethylene-vinyl alcohol copolymers, and (meth)acrylic acid or its anhydride-vinyl alcohol copolymers. starches; sodium alginate; water-soluble polymers such as polyethylene oxide polymers; and known materials such as oxazoline polymers.

<Embodiment of Method for Determining Reusability of Support Film>
An embodiment of the method for judging whether or not a support film can be reused according to the present invention will be described below with reference to the flowchart shown in FIG.

In the measurement condition setting step (S1-1), the measurement conditions of the optical measurement means are set. For example, based on the data (e.g., thickness, refractive index, etc.) related to the transfer film formed on the support film, the measurement conditions are set to emphasize the thickness or material of the transfer film residue. do.

As a result, it is possible to improve the detection accuracy of the transfer-receiving film residue in the optical measurement means. In addition, by using a hyperspectral camera, light of emphasized wavelengths can be easily visualized, and further processing such as the contour clarification step in the latter stage can be performed quickly and accurately. In addition, accurate and high-speed processing can be performed by measuring the reference in advance using materials with known optical constants (e.g., Si wafers, unused support films, etc.) and correcting for the influence of the light source spectrum. Become.

The light sources include xenon lamps, halogen lamps, white LED lamps, near-infrared hyperspectral imaging lighting (LDL-222X42CIR-LACL manufactured by CCS Co., Ltd., etc.), and emits light from deep ultraviolet to near-infrared wavelengths. A laser-excited white light source (KLV XWS-65, etc.) or the like can be used.

As an example of setting the measurement conditions of the optical measurement means by spectral interferometry so that the thickness of the transfer film residue is emphasized using the data of the thickness and refractive index of the transfer film, the optical measurement means A method for adjusting the light receiving position and a method for adjusting the emission wavelength of the light source of the optical measuring means will be described.

In the method of adjusting the light-receiving position of the optical measuring means, the light-receiving position of the optical measuring means can be accurately measured based on the thickness and refractive index of the transferred film ( In other words, it is possible to set the position, angle, and light source conditions that can emphasize the transfer-receiving film residue.

Specifically, the reflected light A reflected on the surface of the transfer-receiving film residue is refracted by the surface of the transfer-receiving film residue, enters the transfer-receiving film residue, is reflected by the support film surface, and is transferred again. When the optical path difference of the reflected light B refracted on the surface of the film residue becomes a multiple of the emission wavelength λ of the light source and the phases of the reflected lights are aligned, the reflected lights are strengthened by interference. Conversely, when the phases are reversed, they weaken each other, and the spectrum of the white light from the light source is converted into a waveform that becomes stronger or weaker depending on the wavelength, and reflected light is obtained.

By using a hyperspectral camera to measure the interference spectrum of the reflected white light emitted from the transported film, it is possible to measure the residue of the film to be transferred and other adhering foreign matter on the entire surface of the support film. there is

By using a hyperspectral camera in this way, it is possible to easily measure foreign matter such as transfer film residue. However, since the wavelength resolution is about every 5 nm, sufficient measurement accuracy may not be obtained for the interference period. If the obtained waveform (interference spectrum) cannot be adequately fitted, there is a problem that the calculated film thickness deviates significantly.

Therefore, in the present invention, it is preferable to input in advance the following information that greatly affects the interference spectrum. As a result, it is possible to improve the accuracy of calculating the film thickness of the transfer-receiving film residue to be measured.

The following four points are effective information for predicting the interference spectrum.
[1] Thickness of support film (d1)
[2] Refractive index of support film (n1)
[3] Thickness (d2) of transferred film formed on support film
[4] Refractive index (n2) of the transferred film formed on the support film

By predicting the presumed waveform (interference spectrum) based on this information and evaluating the similarity with the obtained hyperspectral image, it is possible to determine whether it can be reused at high speed and with high accuracy. In particular, from the above four pieces of information, it is possible to estimate a wavelength region that can be calculated with high accuracy even with the resolution of a hyperspectral camera, and conversely, a wavelength region with low accuracy. In the present invention, it is preferable to perform cutoff so as not to use such a wavelength range in which accuracy is expected to be insufficient for calculation.

In addition, the wavelength region where such accuracy is expected to be insufficient may be scattered by additives such as fine particles, ultraviolet absorbers, antioxidants, etc. contained in the transferred film, and other wavelengths may It can also be removed from the light source to reduce the accuracy of the calculation from the spectrum of the region. By performing such processing, it is possible to emphatically measure the portion of the transferred film remaining (peeling residue) on the support film, and to provide a system capable of high-precision and high-speed determination.

In order to remove the wavelength range where the accuracy is expected to be insufficient, for example, the light source itself may be changed, or a cut filter, mirror, prism, etc. may be inserted between the light source and the film to be measured.

When the refractive index data of the transferred film is used as the data on the transferred film, and the measurement conditions are set to emphasizing the material (refractive index) of the object to be detected, for example, metal powder, the refractive index is It is also possible to detect the number of objects different from the transfer-receiving film. As a result, it becomes possible to determine with high accuracy whether or not the device can be reused in the subsequent determination step.

In the measurement step (S1-2), optical measurement means is used to measure data on the transfer-receiving film residue remaining on the support film.

More specifically, an image is taken on the support film using an optical measuring means, image data is obtained, image processing, etc. get the data. The "data relating to the transfer-receiving film residue" includes image data and various data obtained by image processing.

The measurement step is performed while conveying the support film. A higher conveying speed is preferable from the viewpoint of measurement efficiency, but it must be determined in consideration of the required measurement accuracy and the ability of the optical measuring means to be used. The conveying speed is preferably in the range of 3 to 100 m/min, more preferably in the range of 5 to 70 m/min, and even more preferably in the range of 10 to 50 m/min.

As the optical measuring means, those capable of measuring the entire surface of the support film in the lateral direction are preferable. As such optical measurement means, for example, as shown in FIG. A device having a combined imaging unit can be used. A hyperspectral camera can image an object at multiple wavelengths with high resolution, so it is possible to quantify the film thickness of the object over a wide range in a single measurement.

In the judgment step (S1-3), the judging means judges whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the data on the transfer-receiving film residue measured in the measurement step.

A device such as a computer including a PLC (programmable logic controller) can be used as the determination means. Further, the optical measurement means can also serve as the determination means by providing a determination unit and a program for determination. That is, in the present invention, different devices can be used separately for the optical measuring means and the judging means, or a single device serving as both means can be used.

When the data on the transfer film residue measured in the measuring step is image data, the image data is subjected to image processing, etc. as necessary to obtain more detailed data on the transfer film residue, for example, the transfer film Data such as the number of residuals and the area and minimum width of each transfer-receiving film residual are acquired.

Data such as the area and minimum width of the transfer film residue are calculated from the clarified contour of the transfer film residue, for example, by clarifying the contour of the transfer film residue from the HOG (Histograms of Oriented Gradients) feature amount obtained by image processing. can do.

"HOG feature amount" is a feature amount obtained by histogramming local image gradients. By acquiring the HOG feature amount, it is possible to detect the transfer-receiving film residue and clarify its contour. The HOG feature amount can be calculated with reference to various known papers and Japanese Patent Application Laid-Open No. 2018-36689.

As another method, the contour of the residue may be clarified depending on whether or not the acquired reflection spectrum distribution has a frequency component equal to or higher than the frequency component expected from the film thickness of the transferred film.

Based on the above data such as the number of transfer film remnants and the area and minimum width of each transfer film remnant, it is possible to determine whether the support film cannot be reused even if it is washed, or can be reused after washing. or if it can be reused without cleaning.

　Figs. 3 and 4 are examples of flow charts after the reusability determination.

The support film determined to be reusable without washing in the reusability determination can be wound up and used as a support film roll, and can be continuously transferred and laminated as it is without being wound up after the determination. It can also be reused in the film manufacturing process.

The support film judged to be reusable by washing in the reusability judgment is washed in the washing process described later. The support film after washing may be wound up or reused as it is as shown in the flowchart shown in FIG. you can go

Next, an example of a reusability determination method different from the above-described embodiment will be described using the flowchart shown in FIG.

FIG. 2 is a flow chart of the reusability determination method in which the measurement steps consist of a first measurement step and a second measurement step. Since the measurement condition setting step (S2-1) and the determination step (S2-4) are the same as the measurement condition setting step (S1-1) and the determination step (S1-3), respectively, the first measurement step ( S2-2) and the second measurement step (S2-3) will be described below.

In the first measurement step (S2-2), optical measurement means is used to measure the position of the transferred film residue remaining on the support film.

More specifically, an image is captured on the support film using an optical measuring means, image data is obtained, and image processing is performed on the image data to obtain the support film of the transferred film residue. Get top location data.

The optical measuring means used in the first measuring step (hereinafter also referred to as "first optical measuring means") is capable of acquiring position data and capable of measuring the entire surface of the support film in the lateral direction. is preferred. As such optical measurement means, for example, as shown in FIG. (RMSL8K76CL manufactured by Nippon Electro-Device Co., Ltd.) can be used. With this device, a resolution of about 0.1 mm is obtained when the distance L from the support film to the lens is 1300 mm.

In the second measurement step (S2-3), the thickness or material (refractive index, etc.) of the transferred film residue remaining at the position measured in the first measurement step is measured.

The optical measuring means used in the second measuring step (hereinafter also referred to as "second optical measuring means") is preferably one that can acquire high-resolution image data of the transfer-receiving film residue according to the position data. As such optical measurement means, for example, as shown in FIGS. ), a mount adapter 204, a monochrome line sensor camera 205 (RMSL4K100CL manufactured by Nippon Electro-Device Co., Ltd.), and a high-speed lateral movement mechanism 206 can be used. 7A is a schematic diagram viewed from the front in the width direction, and FIG. 7B is a schematic diagram viewed from the front in the transport direction.

The second optical measurement means is installed downstream of the first optical measurement means in the conveying direction of the support film. The interval between the imaging positions by the first optical measuring means and the second optical measuring means can be arbitrarily set according to the required imaging interval in consideration of the transport speed and the controllability of each optical measuring means. can. For example, if the conveying speed is 5 m/min and the necessary imaging interval is 1 minute, the interval between the imaging positions by the first optical measuring means and the second optical measuring means should be 5 m or more.

In the method for determining whether or not the support film can be reused, the above steps can be consistently executed by a computer, or can be consistently executed by a user's operation. Furthermore, some of the steps may be executed mainly by a computer, and some of the steps may be executed by user operations.

　When a computer is the subject of execution, a reusability judgment program that causes the computer to execute each step is used.

<Washing method for support film>
The method for cleaning a support film of the present invention is a method for cleaning a support film used in the production of a laminate by the peel-transfer method, and it is determined that cleaning is necessary by the method for determining reusability of a support film of the present invention. In this case, the transfer-receiving film remnants remaining on the support film are removed based on the measured data relating to the transfer-receiving film remnants.

The method for removing the transfer-receiving film residue is not particularly limited, but suitable methods include dry ice blasting and adhesive roller processing.

Dry ice blasting will be described below as an example of a method for removing the transfer-receiving film residue.

In the dry ice blasting process, dry ice blasting material (dry ice pellets) is accelerated and jetted with compressed air to blow and remove the transfer film residue remaining on the support film. As a result, the surface of the support film can be washed without being damaged.

The direction in which the dry ice blast material is sprayed is preferably the direction opposite to the transport direction of the support film. As a result, the force of the dry ice blast material is efficiently transmitted to the surface of the support film, making it possible to easily remove the transfer-receiving film residue.

Also, in order to prevent dew condensation on the surface of the support film, it is preferable to set the temperature of the support film to room temperature or higher. For example, the surface temperature of the support film is 20-120°C. Note that it is necessary to pay attention to the melting temperature depending on the composition of the support film. By setting the surface temperature of the support film to 20 to 120° C. in this way, it is possible to prevent the temperature of the support film from lowering when the dry ice blast material is sprayed thereon, thereby preventing dew condensation. It becomes possible.

As a method of raising the temperature of the support film, there is a method of blowing air onto the support film with a dryer or the like before blowing the dry ice blast material onto the support film. As another method, before the dry ice blasting material is sprayed on the support film, a support member such as a roller member or a belt member for conveying the support film is heated, so that the support member in contact with the support member is heated. The film may be heated. For example, the support film is heated by a support member having a temperature higher than the surface temperature of the support film, and the temperature of the support member is adjusted so that the surface temperature of the support film is 20 to 120°C. As a result, the support film can be prevented from being cooled too much, and dew condensation on the support film can be prevented in the step of spraying the dry ice blast material and the subsequent step. As a method for heating the supporting member, hot water or the like may be passed through the roller member, or an electric jacket roll may be used as the roller member.

In addition, since there is a risk of condensation due to cooling by dry ice, it is preferable to lower the dew point of the atmosphere before, during, and after the dry ice blasting material is sprayed. For example, it is desirable to lower the dew point to 10°C or less, more preferably less than 0°C. Specifically, the spraying process is performed in a chamber or the like, and the chamber is filled with sublimated carbon dioxide gas, nitrogen gas, or the like to lower the dew point. Alternatively, for example, the chamber may be filled with dry air having a dew point of −60° C., and a dry ice blast material may be sprayed onto the support film in that environment.

For dry ice blasting, it is preferable to use a blasting nozzle for blowing dry ice blasting material and a suction nozzle for sucking the removed transfer film residue. When the transfer-receiving film residue is removed from the support film with a dry ice blasting material, the removed transfer-receiving film residue floats around the support film. If this state is left as it is, the removed residue of the transfer-receiving film may reattach to the support film, and the support film may be contaminated. By sucking and rapidly discharging the transfer-receiving film residue removed by the dry ice blasting material in this way, it is possible to prevent reattachment to the support film.

For example, as shown in FIG. 8, a blasting nozzle 20 is installed obliquely to a support film 23 on a conveying roller 22, and a blasting material is sprayed obliquely onto the support film 23 to remove the transferred film residue. In this case, a suction nozzle 21 is installed on the opposite side of the blowing, and the transferred film residue peeled off from the support film 23 by the blowing of the dry ice blast material is sucked by the suction nozzle 21 and quickly discharged.

Further, as shown in FIG. 9, the suction nozzle 21 is installed so as to surround the portion of the support film 23 to which the dry ice blasting material is sprayed, by setting the suction nozzle 21 so as to surround the blast nozzle 20 . Alternatively, the peeled transfer-receiving film residue may be sucked and quickly discharged. Wind pressure generated when the dry ice blasting material sublimates is generated in all directions of the part to which the blasting material is sprayed. Residues can be aspirated and quickly discharged.

In order to prevent the transfer-receiving film residue removed by blowing the dry ice blasting material from adhering to the support film surface again, the surface of the support film is discharged while the static electricity is removed using a static eliminator. Dry ice blast material may be sprayed on the surface. Moreover, static elimination may be performed before the dry ice blasting material is sprayed. For example, static elimination is performed by determining the static elimination conditions so that the charge amount of the support film after the dry ice blasting material is sprayed is 1 [kV] or less. By removing the charge until the charge amount becomes 1 [kV] or less, it is possible to prevent the removed transfer-receiving film residue from adhering to the support film again, and furthermore, dust in the atmosphere adheres to the support film. can be prevented. As a specific means, an electrode for generating ions is provided in a blasting nozzle for spraying dry ice blasting material, and the surface of the support film is neutralized while spraying the blasting material.

Further, after removing the transferred film residue from the surface of the support film by spraying dry ice blast material, the support film may be further washed by a known cleaning method. Known cleaning methods include, for example, air web cleaners, sticky web cleaners, or brush web cleaners.

In addition, when the dry ice blasting material is sprayed on the surface of the support film, the support film may be stored in a sealed chamber, and the pressure inside the chamber may be reduced from the outside to spray the dry ice blasting material. For example, the pressure is reduced by about 10 Pa from the pressure outside the chamber. By spraying the dry ice blasting material under such a reduced pressure, it is possible to prevent remnants of the transfer-receiving film removed by the spraying from adhering again to the surface of the support film. Even if the pressure is reduced by about 10 Pa, the dry ice blasting material sublimes into gas, so the effect of the dry ice blasting process is not impaired.

Further, it is preferable to wash the support film after removing the transfer-receiving film residue with a dry ice blasting material. For example, the support film after washing with a dry ice blasting material is immersed in a water tank containing water to remove the residue of the transferred film remaining on the surface of the support film. Further, by washing the support film with a washing agent, the remaining transfer-receiving film residue can be removed more effectively. A washing liquid may be sprayed onto the support film at high speed to remove remaining transfer-receiving film residue. In addition, by irradiating the support film with ultrasonic waves using an ultrasonic cleaner or an ultrasonic transmitter, the remaining transfer-receiving film residue can be effectively removed. Also, instead of washing, saponification may be performed. Alternatively, a cleaning agent may be sprayed onto the support film being conveyed while being placed on the belt member or the support film being wound around the roller member to remove the remaining transfer-receiving film residue. good. For this cleaning agent, for example, water or water to which an active agent or the like is added is used. After removing transfer-receiving film residues remaining on the support film using a cleaning agent, the support film is washed with water and then dried. The washing liquid is passed through a filter so as to be free of foreign matter, and after washing, the washing liquid on the support film is dried.

Alternatively, the dry ice blasting material may be sprayed onto the support film in multiple batches. For example, a plurality of dry ice blasting devices are provided, and dry ice blasting materials having the same particle size or different particle sizes are sprayed onto the support film from each dry ice blasting device. Dry ice blasting equipment has a limit to the amount of dry ice blasting material that can be generated, so if the amount of dry ice blasting material to be used is large, it is better to install multiple dry ice blasting equipment for processing. . In other words, if only one dry ice blasting device is provided for processing, the amount of dry ice blasting material generated is insufficient, and there is a risk that the transfer-receiving film residue cannot be satisfactorily removed. Therefore, by providing a plurality of dry ice blasting devices and blowing the dry ice blast material in a plurality of times, it is possible to sufficiently remove the transfer-receiving film residue.

<Manufacturing method of transferable laminated film roll>
The method for producing a transferable laminated film roll of the present invention is a method for producing a transferable laminated film roll, which is a roll body of a transferable laminated film, and cleaning is unnecessary by the method for determining whether or not a support film can be reused according to the present invention. A transfer-receiving film is laminated on the determined support film or the support film washed by the method for washing a support film of the present invention to prepare a transferable laminated film, and the transferable laminated film is wound up. and manufacturing a transferable laminated film roll.

"Transferable laminated film" refers to a laminated film in which at least a transfer-receiving film is laminated on a support film.

The type of film to be transferred laminated on the support film is not particularly limited, and examples include retardation films, polarizing films, protective films, hard coat films, release films, release films, base films, light absorbing films, and the like. can be laminated.

The resin material of the transfer-receiving film formed on the support film is not particularly limited. It is possible to use one or more kinds of resins, cellulose ester resins, polyamide resins, polyimide resins, and styrene resins.

Among these, it is preferable to contain a polymer material having a polar group such as a carbonyl group, an ester group, or an amide group, which can give a certain level of adhesive strength to the support film, the adhesive layer, and the like. Therefore, (meth)acrylic resins, styrene/(meth)acrylate copolymers, diester fumarate resins, polyamide resins, polyimide resins, some cycloolefin resins, cellulose ester resins, etc. are used. is preferred.

More specifically, the (meth)acrylic resin is a copolymer containing structural units derived from (meth)acrylic acid ester/phenylmaleimide as described in JP-A-2021-89301. Preferably.

The cycloolefin-based polymer is preferably a polymer described in Japanese Patent No. 2977274 or a polymer obtained by polymerizing a cycloolefin monomer as described in Japanese Patent Application Laid-Open No. 2017-82143.

As the fumaric acid ester-based resin, it is preferable to use the polymers described in Japanese Patent No. 6572532, Japanese Patent No. 5298535, Japanese Patent No. 5262013, and the like.

The polyimide-based resin is preferably a soluble transparent polyimide resin described in JP-A-2014-151559, JP-A-2019-59834, JP-A-2021-59731, etc., which have excellent optical properties. Moreover, it may be a composition in which a plurality of types of polyimide resins are blended as described in International Publication No. 2019/203037.

Examples of cellulose ester-based resins include mixed fatty acid esters such as cellulose acetate propionate and cellulose acetate butyrate described in JP-A-10-45804, JP-A-08-231761, and US Pat. No. 2,319,052. can be used. Among them, cellulose triacetate and cellulose acetate propionate are preferred.

In addition, it can also be applied to a method for producing a film in which transfer is performed after UV curing, as described in JP-A-2018-045220.

The transfer film according to the present invention may further contain an additive as necessary, and may contain an additive having a molecular weight of 1000 or less within the range of 0.0001 to 1% by mass relative to the transfer film. preferable. Examples of other components include known antioxidants, rubber particles, matting agents (fine particles), plasticizers, ultraviolet absorbers, antistatic agents, and the like. A more preferable content is in the range of 0.001 to 0.1% by mass. However, with respect to rubber particles, for matrix polymers (acrylic polymers, etc.) that have approximately the same refractive index and do not lose optical properties, any amount (1 to 90 mass %, preferably 20 to 80% by mass) may be added.

A known antioxidant can be used. In particular, lactone, sulfur, phenol, double bond, hindered amine, and phosphorus compounds can be preferably used. By adding these, it is possible to improve the storage stability of the transfer-receiving film over time. Specifically, lactone compounds such as "IrgafosXP40, IrgafosXP60 (trade name)" manufactured by BASF Japan Ltd., sulfur compounds such as "Sumilizer TPL-R" and "Sumilizer TP-D" manufactured by Sumitomo Chemical Co., Ltd. , BASF Japan Co., Ltd. "Irganox (registered trademark) 1076", "Irganox (registered trademark) 1010", ADEKA Co., Ltd. "Adekastab (registered trademark) AO-50" phenolic compounds, Sumitomo Chemical Co., Ltd. Double bond compounds such as "Sumilizer (registered trademark) GM" and "Sumilizer (registered trademark) GS" manufactured by BASF Japan Co., Ltd. "Tinuvin (registered trademark) 144" and "Tinuvin (registered trademark) 770" , Hindered amine compounds such as "ADK STAB (registered trademark) LA-52" manufactured by ADEKA Corporation, "Sumilizer (registered trademark) GP" manufactured by Sumitomo Chemical Co., Ltd., "ADK STAB (registered trademark)" manufactured by ADEKA Corporation PEP-24G", "ADK STAB (registered trademark) PEP-36" and "ADK STAB (registered trademark) 3010", "IRGAFOS P-EPQ" manufactured by BASF Japan, "GSY- P101", an acid scavenger as described in US Pat. No. 4,137,201, and the like. These antioxidants can be used alone or in combination of several different types of compounds.

A rubber particle is a particle containing a rubber-like polymer. Rubber particles are added mainly for the purpose of improving the flexibility of the transferred film. A rubber-like polymer is a soft crosslinked polymer having a glass transition temperature of 20° C. or less. Examples of such crosslinked polymers include butadiene crosslinked polymers, (meth)acrylic crosslinked polymers, and organosiloxane crosslinked polymers. Among them, a (meth)acrylic crosslinked polymer is preferable from the viewpoint that the refractive index difference with the (meth)acrylic resin is small and the transparency of the film to be transferred is less likely to be impaired. polymer) is more preferred.

Examples of ultraviolet absorbers include benzotriazole-based, 2-hydroxybenzophenone-based, and salicylic acid phenyl ester-based ones. For example, 2-(5-methyl-2-hydroxyphenyl)benzotriazole, 2-[2-hydroxy-3,5-bis(α,α-dimethylbenzyl)phenyl]-2H-benzotriazole, 2-(3, Triazoles such as 5-di-t-butyl-2-hydroxyphenyl)benzotriazole, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone benzophenones such as

Examples of fine particles include inorganic compounds such as silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, calcium carbonate, calcium carbonate, talc, clay, calcined kaolin, calcined calcium silicate, hydrated calcium silicate, aluminum silicate, Mention may be made of magnesium silicate and calcium phosphate. Fine particles of organic compounds can also be preferably used. Examples of organic compounds include polytetrafluoroethylene, cellulose acetate, polystyrene, polymethyl methacrylate, polypropyl methacrylate, polymethyl acrylate, polyethylene carbonate, acrylic styrene resins, silicone resins, polycarbonate resins, benzoguanamine resins, and melamine resins. , Polyolefin powder, polyester resin, polyamide resin, polyimide resin, polyfluoroethylene resin, pulverized classified products of organic polymer compounds such as starch, and polymer compounds synthesized by suspension polymerization can be used. can.

The thickness of the transferred film formed on the support film is not particularly limited. The support film can be suitably reused in forming a transfer-receiving film having a thickness of 20 μm or less. The thickness may be more than 20 μm (for example, 40 μm), preferably 1 to 20 μm, more preferably 3 to 10 μm.

The method of forming the transferred film on the support film is not particularly limited, and is formed by a conventionally known solution casting method such as a comma coater, gravure, reverse gravure, slot die, slide coater, or a melt casting method. can do.

<Manufacturing Equipment for Transferable Laminated Film Roll>
The production method of the transferable laminated film roll of the present invention can be carried out using, for example, the production apparatus shown in FIG.

FIG. 10 is a schematic diagram of a manufacturing apparatus B200 that can be used in the method for manufacturing a transferable laminated film roll of the present invention. The manufacturing apparatus B200 has a supply section B210, a coating section B220, a drying section B230, a cooling section B240, and a winding section B250. Ba to Bd indicate transport rolls that transport the support film B110.

The supply unit B210 has a delivery device (not shown) that delivers a roll B201 of the band-shaped support film B110 wound around the core. The support film B110 is a support film that has been determined not to require cleaning by the method for determining reusability of a support film of the present invention, or a support film that has been cleaned by the method for cleaning a support film of the present invention. The roll B201 may be a film roll manufactured by the method for manufacturing a support film roll of the present invention.

The coating unit B220 is a coating device, and includes a backup roll B221 that holds the support film B110, a coating head B222 that coats the support B110 held by the backup roll B221 with the solution for the transferred film, and a coating head. and a decompression chamber B223 provided upstream of B222.

The flow rate of the transfer film solution discharged from the coating head B222 can be adjusted by a pump (not shown). The flow rate of the transfer film solution discharged from the coating head B222 is set to an amount that can stably form a coating layer of a predetermined thickness when continuous coating is performed under the conditions of the coating head B222 adjusted in advance.

The decompression chamber B223 is a mechanism for stabilizing the bead (collection of coating solution) formed between the solution for the film to be transferred from the coating head B222 and the support film B110 during coating, and adjusts the degree of decompression. It is possible. The decompression chamber B223 is connected to a decompression blower (not shown) so that the inside is decompressed. The decompression chamber B223 is in a state without air leakage, and the gap with the backup roll is adjusted to be narrow, so that a stable bead of the coating liquid can be formed.

The drying section B230 is a drying device that dries the coating film applied to the surface of the support film B110, and has a drying chamber B231, a drying gas inlet B232, and an outlet B233. The temperature and air volume of the drying air are appropriately determined depending on the type of the coating film and the type of the support film B110. By setting conditions such as the temperature and air volume of the drying air and the drying time in the drying section B230, the amount of residual solvent in the coating film after drying can be adjusted. The amount of residual solvent in the coating film after drying can be measured by comparing the unit mass of the coating film after drying with the mass after sufficiently drying the coating film.

The present invention will be specifically described below with reference to examples, but the present invention is not limited to these. In the examples, "parts" or "%" are used, but "mass parts" or "mass%" are indicated unless otherwise specified.

<Preparation of support film after use>
In order to determine whether it can be reused, as described below, an optical film is laminated on a support film as a film to be transferred to form a transferable laminated film, and after aging, the film to be transferred is peeled off. support film” was obtained.

(Support film)
As a support film, a polyethylene terephthalate film (PET film, Therapyl HP2 manufactured by Toray Industries, with a release layer containing a non-silicone release agent, processed into a thickness of 75 μm, a width of 1,300 mm, and a length of 1,000 m, with a refractive index of 1.66) was used. Using. The refractive index is a value measured under an environment of 23° C. and 50% RH.

(Preparation of solution for transferred film)
A mixed solution was prepared by mixing the following materials.
Methyl ethyl ketone (boiling point 80°C) 900 parts by mass Acrylic resin 80 parts by mass Acrylic rubber particles 20 parts by mass

MMA/PMI/MADA copolymer (60/20/20 mass ratio, Mw: 1,500,000, Tg: 137°C) was used as the acrylic resin. Moreover, each abbreviation is as follows.
MMA: methyl methacrylate PMI: phenylmaleimide MADA: adamantyl acrylate

The above acrylic rubber particles were synthesized based on the method described in JP-A-2021-89301. The average primary particle size was 200 nm.

Furthermore, a dispersing agent (sodium polyoxyethylene lauryl ether phosphate: molecular weight 332) was added to the mixture in an amount of 0.3% by mass in the transfer film to obtain a transfer film solution.

(Preparation of transferred film)
After applying the transfer film solution to the release layer of the support film by a back coating method using a die at a conveying speed of 10 m / min, the transfer film is dried by the following initial drying and post-drying. bottom.

(initial drying)
1st step: 1 minute at 40°C 2nd step: 1 minute at 70°C 3rd step: 1 minute at 100°C 4th step: 2 minutes at 130°C (post drying)
Fifth step: 15 minutes at 120°C

A transfer-receiving film having a thickness of 3 μm and a refractive index of 1.50 was produced on the support film by the above process. The refractive index is a value measured under an environment of 23° C. and 50% RH.

(Aging process)
The film to be transferred on the support film and the adhesive film were laminated, and an aging process was performed. Specifically, the release film of the adhesive film (PET75-T723N(6) manufactured by Nisei Shinka Co., Ltd., release film 19 μm/adhesive layer 6 μm/surface substrate 75 μm) is peeled off, and the transferred film is supported. An adhesive film was attached to the surface opposite to the body film. After lamination, the support film/transferred film/adhesive layer/surface base material were laminated in a state of being wound up and allowed to stand for one week.

After the aging process, the support film and the transferred film were continuously separated by a roll conveyor. While peeling, the support film was wound up to obtain a "used support film".

<Reusability determination (1)>
Using a reusability determination system, the reusability determination was performed for the above-mentioned "support film after use". FIG. 11 shows a block diagram of the reusability determination system used.

In this embodiment, as optical measurement means, a high-intensity condensing line illumination 301 (LDL-222X42CIR-LACL manufactured by CCS Corporation) and a line scan type hyperspectral camera 303 (Pika XC2 manufactured by Resonon) are used as shown in FIG. A device equipped with the combined imaging unit was installed and used on the transport line of the transport means. The optical measurement means includes an imaging unit that acquires image data, an image processing unit that processes the image data, a transmission/reception unit that transmits various data acquired by the imaging unit and the image processing unit to the determination unit, and and a control unit for controlling the processing.

The determining means includes a transmitting/receiving section for receiving various data transmitted from the optical measuring means, an image processing section for performing image processing on image data, and determining whether or not the support film can be reused, including whether it is necessary to wash the support film. A computer including a determination unit, a display unit for displaying various data and determination results, and a control unit for controlling each process was used.

In this example, the reusability of the film was determined according to the procedure of the flowchart shown in FIG. In addition, the measurement condition setting step is performed by user operation, and the subsequent steps are performed mainly by the optical measurement means and the determination means using a reusability determination program that causes the optical measurement means and the determination means to execute each step. went.

Of the steps in the flowchart shown in FIG. 13, (S3-2) to (S3-5) are included in the measurement steps, and (S3-2) to (S3-5) are included in the determination steps. Each step will be described below.

In the measurement condition setting step (S3-1), the light-receiving position of the entire surface thickness gauge, which is an optical measuring means, is set to the remaining object of the transfer film based on the data on the transfer film formed on the support film. It is set at a position where the thickness is emphasized.

Specifically, we first determined the angle at which the phases of the reflected light are aligned based on the following data. In other words, the reflected light A reflected on the surface of the transfer film residue is refracted by the surface of the transfer film residue, enters the transfer film residue, is reflected by the support film surface, and is reflected again by the transfer film residue. The angle at which the optical path difference of the reflected light B refracted at the surface is a multiple of the emission wavelength λ of the light source was obtained.

[1] Thickness of support film (d1): 75 μm
[2] Refractive index of support film (n1): 1.66
[3] Thickness of transferred film (d2): 3.0 μm
[4] Refractive index of transferred film (n2): 1.50
[5] Peak wavelength of light source: 780 nm

The light-receiving position of the optical measurement means was adjusted so that the incident angle and the reflection angle were angles at which the phases of the reflected light obtained above were aligned.

Further, based on the data of [1] to [5] above, the obtained interference spectrum is predicted, the frequency components of the interference spectrum of the support film are removed, and the frequency components of the interference spectrum of the transferred film are emphasized. The calculation wavelength range was set as follows.

In the imaging step (S3-2), the "used support film" conveyed by the conveying means at a speed of 5 m/min is photographed using a thickness gauge on the entire surface in the width direction, and the image data is obtained. Two-dimensional reflectance spectral distribution data were acquired.

In the film thickness data calculation step (S3-3), the film thickness according to the light spectrum was calculated by performing image processing on the reflection spectrum distribution data obtained above.

In the three-dimensional image data generation step (S3-4), the transfer film residue is detected from the film thickness calculated above, the distance of the transfer film residue in the width direction x length direction x film thickness direction is obtained, 3D image data to be displayed was generated.

At the 3D image data transmission step (S3-5), the generated 3D image data was transmitted to the determination means.

In the three-dimensional image data receiving step (S3-6), the determination means received the generated three-dimensional image data from the optical measurement means.

In the HOG feature amount calculation step (S3-7), the HOG feature amount was calculated by executing image processing on the received three-dimensional image data.

In the contour clarification step (S3-8), the contour of the transferred film residue was clarified using the HOG feature amount calculated above.

In the area/minimum width calculation step (S3-9), the area and minimum width of the transfer-receiving film residue whose outline was clarified were calculated.

In the reusability determination step (S3-10), based on the film thickness, minimum width, area, and number of remaining objects on the transfer film, if the support film cannot be reused even after washing, Those that can be reused without washing are judged as “reusable (washing required)”, and those that can be reused without washing are judged as “reusable (no washing required)”.

Table I shows the determination criteria used in the example and the results determined in the reusability determination step (S3-10). In addition, as implementation data, the steps (S3-1) to (S3-9) are performed on two "support films after use" (Sample 1 and Sample 2) similarly prepared by the above method. The results obtained by

By executing the steps (S3-1) to (S3-10), it was possible to obtain the judgment result that the sample 1 was "reusable (requires cleaning)". In addition, the sample 2 was able to obtain the judgment result of "reusable (no cleaning required)".
In the above judgment, the judgment that it can be reused by washing is made by assuming the washing performance in the dry ice blast treatment described later, but in the case of another washing method or the material of the transfer film・When the film thickness is different, it is possible to set appropriate criteria for each.

<Reusability determination (2)>
Using a reusability determination system, the reusability determination was performed for the above-mentioned "support film after use". FIG. 12 shows a block diagram of the reusability determination system used.

As the first optical measurement means, as shown in FIG. 6, a high-intensity condensing line illumination 101 (LN-GA manufactured by CCS Co., light source peak wavelength 465 nm), a lens 102 (XL501 manufactured by Myutron Co., Ltd.), and a monochrome line A device equipped with an imaging unit combined with a sensor camera 103 (RMSL8K76CL manufactured by Nippon Electro-Device Co., Ltd.) was installed on the transport line of the transport means and used. The first optical measurement means includes the imaging section for acquiring image data, an image processing section for image processing the image data, and transmission of various data acquired by the imaging section and the image processing section to the second optical measurement means. and a control unit for controlling each process.

As the second optical measurement means, as shown in FIGS. 7A and 7B, a high-intensity condensing line illumination 201 (LN-D2 manufactured by CCS Co., Ltd.), a half mirror box 202, a lens 203 (XLS01 manufactured by Myutron Co., Ltd.), A device equipped with an image capturing unit comprising a combination of a mount adapter 204, a monochrome line sensor camera 205 (RMSL4K100CL manufactured by Nippon Electro-Device Co., Ltd.), and a high-speed lateral movement mechanism 206 was installed on the transport line of the transport means. The second optical measurement means includes the imaging section that acquires image data, an image processing section that performs image processing on the image data, a transmission/reception section that transmits and receives various data to and from the first optical measurement means and determination means, and a control unit for controlling each process. In addition, since the second optical measurement means can take an image with specular reflection, high-resolution image data can be obtained.

In the second optical measuring means, the interval between the imaging positions of the first optical measuring means and the second optical measuring means is 20 m (1 minute in terms of time since the conveying speed is 20 m/min). , was installed downstream of the first optical measuring means in the direction of transport of the support film.

The determining means includes a transmitting/receiving section for receiving various data transmitted from the second optical measuring means, an image processing section for performing image processing on image data, and determining whether or not the support film can be reused, including whether it needs to be washed. A computer including a determination unit for determination, a display unit for displaying various data and determination results, and a control unit for controlling each process was used.

In this example, the reusability of the support film was determined according to the procedure of the flowchart shown in FIG. In addition, the measurement condition setting step is performed by user operation, and the subsequent steps are performed mainly by the optical measurement means and the determination means using a reusability determination program that causes the optical measurement means and the determination means to execute each step. went.

Among the steps of the flowchart shown in FIG. 14, (S4-2) to (S4-4) are included in the first measurement step, and (S4-5) to (S4-7) are included in the second measurement step. , (S4-8) to (S4-12) are included in the determination step. Each step will be described below.

In the measurement condition setting step (S4-1), with respect to the transfer-receiving film formed on the support film, the first optical measurement means detects the portion where the peeling residue is estimated to be left over the entire surface. The measurement system was set up so that the existence or non-existence of the transfer-receiving film residue can be confirmed with high precision by the high-resolution measurement means of the optical measurement means.

Specifically, the second optical measurement means was set so that highly directional light was perpendicularly incident on the support film, so that the outline of the transfer-receiving film residue could be accurately obtained. As a result, it is possible to easily see the state of deformation from the change in the amount of light due to unevenness, and to obtain an image suitable for discrimination.

Also, while the resolution of the first optical means is 87.5 μ/pixel, the resolution of the second optical measurement means is set to 14 μ/pixel.

In the first imaging step (S4-2), the entire surface in the width direction is imaged using the first optical measuring means on the "used support film" being transported by the transporting means at a speed of 20 m/min. , acquired low-resolution image data.

In the position data generation step (S4-3), image processing was performed on the low-resolution image data obtained above to generate position data of the detected object assumed to be the transferred film residue. Specifically, a value of ±10% from the average brightness in the range captured at the same time is set as a threshold, and the position of the detected object assumed to be the transferred film residue is the position data that has the brightness outside the threshold. and

In the position data transmission step (S4-4), the generated position data was transmitted to the second optical measuring means installed downstream in the transport direction of the support film.

In the position data receiving step (S4-5), the second optical measuring means receives the generated position data from the first optical measuring means.

In the second imaging step (S4-6), the location on the support film corresponding to the position data generated above was imaged with specular reflection to obtain high-resolution image data. Specifically, the position in the conveying direction is adjusted by aligning the measurement timing using the data converted into the measurement time considering the conveying speed, and the position in the lateral direction is adjusted by the high-speed lateral movement mechanism. By adjusting by moving the imaging unit in the hand direction, the position on the support film corresponding to the position data was imaged.

In the high-resolution image data transmission step (S4-7), the acquired high-resolution image data was transmitted to the determination means.

In the high-resolution image data receiving step (S4-8), the determination means received the acquired high-resolution image data from the second optical measurement means.

In the HOG feature quantity calculation step (S4-9), the HOG feature quantity was calculated by performing image processing on the received high-resolution image data.

In the outline clarification step (S4-10), the outline of the transferred film residue was clarified using the HOG feature amount calculated above.

In the area/minimum width calculation step (S4-11), the area and minimum width of the transfer-receiving film residue whose outline was clarified was calculated.

In the reusability judgment step (S4-12), based on the film thickness, minimum width, area, and number of remaining objects on the transfer film, if the support film cannot be reused even after washing, Those that can be reused without washing are judged as “reusable (washing required)”, and those that can be reused without washing are judged as “reusable (no washing required)”.

Table II shows the determination criteria used in the example and the results determined in the reusability determination step (S4-12). In addition, as implementation data, (S4-1) to (S4-11) for three "support films after use" (Sample 3, Sample 4, and Sample 5) prepared in the same manner as described above. Describe the results obtained by performing the steps.

By executing steps (S4-1) to (S4-12), it was possible to obtain the judgment result that sample 3 was "reusable (requires cleaning)". In addition, the sample 4 was able to obtain the judgment result of "reusable (no cleaning required)". Furthermore, sample 5 was able to obtain the judgment result of "not reusable".

<Washing of support film>
Transfer target obtained by executing steps (S3-1) to (S3-10) for sample 1 for which the judgment result of "reusable (cleaning required)" was obtained in reusable judgment (1) Based on the data on film residue, the transferred film residue remaining on the support film was removed. Details will be described below.

The "support film after use" (Sample 1) was set in the unwinder and conveyed at a conveying speed of 20 m/min. For the support film on the transport line, dry ice blasting is applied to the position where the transfer film remains, based on the data such as the position of the transfer film residue obtained by the support reusability judgment. By doing so, the transfer-receiving film residue remaining on the support film was removed.

The dry ice blasting was performed by installing the blast nozzle 20 and the suction nozzle 21 as shown in FIG. The atmosphere temperature is set to 20°C, the dew point of the atmosphere is set to less than 0°C in a state in which the support film is supported by a roller member (support member) of φ500 mm at a temperature of 20°C, static electricity is removed by a static eliminator, and a suction nozzle is provided. A dry ice blasting material was blown onto the surface of the support film, and finally the support film was completely cleaned with an adhesive web cleaner.

Pellet-like dry ice particles with an average particle size of φ3×2 mm were used as the dry ice blast material. Moreover, the supplied air pressure was 3.5 kg/cm ² .

When the support film washed by the method was subjected to reusability judgment in the same manner as above, the judgment result was "reusable (washing not necessary)", and the residue of the transferred film could be removed by washing. I was able to confirm that there is.

The present invention provides a support film reusability determination method, a reusability determination program, and a reusability determination method that can efficiently and highly accurately determine whether a support film used in laminate production by a peel transfer method can be reused. Use in a method for cleaning a support film, a method for reusing a support film, a method for manufacturing a support film roll, and a method for manufacturing a transferable laminated film roll using a system and a method for determining whether the support film is reusable. can be done.

20 Blast nozzle 21 Suction nozzle 22 Transport roller 23 Support film 101 High-intensity condensing line illumination 102 Lens 103 Monochrome line sensor camera 201 High-intensity condensing line illumination 202 Half mirror box 203 Lens 204 Mount adapter 205 Monochrome line sensor camera 206 High-speed width movement mechanism 301 High-intensity condensing line illumination 303 Line scanning hyperspectral camera B110 Support film B200 Manufacturing apparatus B210 Supply unit B220 Coating unit B230 Drying unit B240 Cooling unit B250 Winding unit

Claims

A method for determining the reusability of a support film used in laminate production by a peel transfer method,
a measuring step of measuring data relating to a transfer-receiving film residue remaining on the support film using an optical measuring means while transporting the support film;
and determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue.
Before the measurement step, a measurement condition setting step for the optical measurement means,
In the measurement condition setting step, setting the measurement condition to a measurement condition that emphasizes the thickness or material of the transfer-receiving film residue based on the data regarding the transfer-receiving film formed on the support film. The method for judging whether or not a support film can be reused according to claim 1.
the measuring step comprises at least a first measuring step and a second measuring step;
In the first measuring step, measuring the position of the transfer-receiving film residue;
3. Judgment as to whether or not the support film can be reused according to claim 1 or claim 2, wherein in the second measuring step, the thickness or material of the transfer-receiving film residue remaining at the position is measured. Method.
A method for cleaning a support film used in laminate production by a peel transfer method, comprising:
When it is determined that cleaning is necessary by the method for determining reusability of a support film according to any one of claims 1 to 3, based on the measured data on the transfer film residue, the A method for washing a support film, comprising removing a transfer-receiving film residue remaining on the support film.
A method for reusing a support film used in laminate production by a peel transfer method,
The support film determined not to require cleaning by the method for determining reusability of a support film according to any one of claims 1 to 3, or the method for cleaning a support film according to claim 4. A method for reusing a support film, comprising: reusing the support film washed by the method as a support for a transfer-receiving film.
A method for manufacturing a support film roll, which is a roll of a support film, comprising:
The support film determined not to require cleaning by the method for determining reusability of a support film according to any one of claims 1 to 3, or the method for cleaning a support film according to claim 4. A method for producing a support film roll, comprising: winding up the support film washed by the above method to produce a support film roll.
A method for producing a transferable laminated film roll, which is a roll body of a transferable laminated film, comprising:
The support film determined not to require cleaning by the method for determining reusability of a support film according to any one of claims 1 to 3, or the method for cleaning a support film according to claim 4. A transferable laminated film is produced by laminating a transfer-receiving film on the support film washed by the method, and the transferable laminated film is wound up to produce a transferable laminated film roll A method for manufacturing a laminated film roll.
A program for determining the reusability of a support film used in laminate production by a peel transfer method,
a measuring step of measuring data relating to a transfer-receiving film residue remaining on the support film using an optical measuring means while transporting the support film;
determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue. program.
A system for determining the reusability of a support film used in laminate production by a peel transfer method,
a conveying means for conveying the support film;
optical measuring means for measuring data relating to transfer-receiving film remnants remaining on the support film during transportation;
and determination means for determining whether or not the support film can be reused, including whether or not the support film needs to be washed, based on the measured data on the transfer-receiving film residue.